Avery Dennison AP4.4 User manual

05/09 Rev. 5.02-01 USER MANUAL
AP4.4 – AP5.4
Setup & Operation
Installing the Printer ......................................2
Unpacking the printer ................................2
Carrying the Printer ................................... 2
Check the Delivery ....................................3
Removing the Transportation Lock ........... 6
Product Description ....................................... 7
Operating Parts AP4.4 / AP5.4 basic ....... 7
Operating parts AP5.4 Dispenser /
Internal Rewinder ...................................... 9
Modes of Operation AP5.4 Dispenser /
Internal Rewinder .................................... 11
Arrangement of the Connections ........... 12
Warning Signs at the Printer ................... 14
Control Panel (Display) ........................... 15
Operating State ....................................... 16
Basic Operating Procedures .......................18
Connecting the Printer .............................18
Setting the Interface .................................19
Activate/Deactivate Internal Rewinder .....19
Activate/Deactivate Dispenser .................20
Configure Dispenser ...............................21
Operation in Offline Mode ........................21
Operation in Online Mode ........................22
Creating a Print job ..................................23
Transferring a Print Job ...........................23
Using CF Cards (AP5.4) .........................24
Setting the Realtime Clock (AP5.4) .........26
Reading out real time with Easy-Plug
(AP5.4) ....................................................26

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Installing the Printer
Unpacking the printer
1. Remove all loose objects from the packaging.
2. Carefully lift the printer together with the polystyrene cushions out of the
box. Have a second person keep hold of the box while you remove the
printer.
[1] AP5.4 in the original packaging.
3. Remove the polystyrene cushions and plastic wrap from the printer. Hav-
ing someone else help you with this will also make it easier!
4. Place the printer on an even surface.
Carrying the Printer
One person can easily carry the AP4.4/5.4 because it only weighs 14kg.
«To carry the printer, grip the baseplate from the front and rear [2].
[2] When lifting the printer, grip under the baseplate!
Packaging ¯Please retain the original packaging for later use when transporting the
printer!
CAUTION! - Observe the following to avoid damaging the printer:
«Do not lift the printer by holding the plastic parts on the front and rear.
«Do not grip the front cover when attempting to carry the printer.

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Check the Delivery
You are bound to want to start using your new AP4.4/5.4 as soon as possible.
However, we would ask you to take a few minutes to check the following:
«Please ensure that the printer has not been damaged in transit. If the pack-
aging has been dented or torn,please check the contents particularly carefully
for damage that may have resulted from transportation.
«Are the following articles listed included in the box?
[3] The following items are delivered with the AP4.4/5.4.
•AP4.4/5.4 Printer
•Power supply cable [3A]
The plug for the power supply is different depending on the country of
delivery.
•Data cable [3B]
Centronics IEEE 1284 CA Cable 2m. The cable connector for the printer
is a type C connector!
•Core adapters [3C]
There are two core adapters each for the material rolls with a core internal
diameter of 76.2mm (3”) and 101.4mm (4”). On delivery, the core adapt-
ers are placed on the printer material dispenser.
•Empty foil core [3D]
Empty foil core for rewinding the thermotransfer foil. On delivery, the back-
ing paper is placed on the foil rewind mandrel.
•Documentation CD [3E]
Contains extensive instructions on using the printer as well as the
Windows driver, printer firmware and service manual.
•Quick reference guide [3F]
Multilingual quick reference guide in print form.
BA F
E
C
DG

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•Size 10 torx screwdriver [3G]
Tool which is used to replace the print roller and to mount a dispensing
edge.
AP5.4 with Cutter Cutter [4]
Only if you ordered the “AP5.4 peripheral with cutter”.
[4] If ordered, you will find the cutter in a special carrier in the top of the printer packaging.
You can find instructions on how to mount the cutter in the Cutter Manual .
¯The cutter hook, a part which is required to mount the cutter, can be found
fixed to the printer bottom.
AP5.4 with Internal
Rewinder •Printer with mounted deflector
•Housing front part, bottom side with screw [5B].
•Cutter flange cover with screws [5A].
¯It is recommended to mount the housing parts, if the printer is used as
a standard device without rewinding function.
[5] These housing parts are shipped loose with the „AP5.4 Internal Rewinder“.
AB

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AP5.4 Dispenser •Printer with mounted dispensing edge
•Housing front part, bottom side with screw [6A].
•Cutter flange cover with screws [6B].
•Deflector [6C].
Enables the AP5.4 Dispenser to be operated with internal (label material)
rewinder.
¯It is recommended to mount the housing parts, if the printer is used as
a standard device without dispensing or rewinding function.
[6] These housing parts are shipped loose with the „AP5.4 Dispenser“.
A
B
C

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Removing the Transportation Lock
1. Open the printer lid.
2. Remove the cable tie holding the printhead inplace [7A]. For this, use side-
cutting pliers or strong scissors.
[7] AP4.4/5.4 transportation lock (A).
AP5.4 Dispenser «Remove the connector from its transport position at the printer bottom and
connect it to the connector at the frontside of the printer.
CAUTION! - Observe the following to avoid damaging the printhead:
«Do not use a knife to cut the cable tie.
A

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Product Description
Operating Parts AP4.4 / AP5.4 basic
[8] Exterior view of the AP5.4.
AControl panel:
LCD graphics display, 4 buttons; displays printer operating status, enables
parameter menu settings.
BConnection for additional devices:
(Not at AP4.4 and AP5.4 basic) Connection for optional cutter or take-up.
CFront cover:
Open to insert material and foil.
DWindow:
Allows material/foil supply check without opening the front hood.
A
B
C
D

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[9] AP5.4 operating parts.
AFoil unwinding roll mandrel:
Holds the new foil roll.
BFoil take-up roll mandrel:
Holds the backing paper onto which used foils are wound.
CFlange mount for additional devices:
Cutter and take-up can alternately be screwed on here. To do this, you will
need to remove the plastic cover.
DPressure lever:
Opening the pressure lever raises the printhead. This is required when in-
serting the material or foil or to clean the printhead or printing roller.
EMaterial rewinder:
Labelling material roller inserted here.
FMaterial strain relief:
Ensures even feed of the labelling material.
GGuide plate:
Prevents the material roll from slipping sideways.
HAdapter rings:
To set the unwinder to the core diameter of the material roll.
A
B
C
D
E
F
G
H

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Operating parts AP5.4 Dispenser / Internal Rewinder
AP5.4 Dispenser
[10] Additional operating parts of the „AP5.4 Dispenser“.
ADispensing edge:
Peels the labels off the backing paper.
BConnector:
Connection of the dispensing edge sensor.
CDispensing roller:
Holds the material web tight over the dispensing edge.
DDispensing roller release button:
Press the red button to release the dispensing roller.
EDeflector:
Deflects the backing paper.
FRewinder:
Wraps up the backing paper.
A
B
C
D
EF

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AP5.4 Internal Rewinder
[11] Additional operating parts of the „AP5.4 Internal Rewinder“.
ADeflector:
Deflects the printed label web without dispensing any labels.
BDeflector:
Deflects the label web.
CRewinder:
Wraps up the label web.
A
BC

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Modes of Operation AP5.4 Dispenser / Internal Rewinder
With the AP5.4 featuring an internal rewinding module, a label can either be
dispensed (using the dispensing edge) or rewound into the printer housing
(using the deflector) after it is printed.
•If the printer’s Dispenser is used, the label is pulled over the dispensing
edge, and the backing paper is rewound.
•If its Rewinder is used, the printed label is redirected by a deflector and re-
wound together with its backing paper.
The electronics of the rewinder regulate the pull force exerted on the backing
papersothatthesameforceis exertedregardlessoftherolldiameter.Thepull
force also depends onthe material width and the printingspeed. Thepullforce
is either regulated automatically using default parameters, or it can be set
manually.
¯Manualsettingisonlyrequiredinspecialcircumstancesandshouldalways
be carried out by a qualified authorised service technician.
After the printer isswitched on, the rewinder is initialised and thelabel material
is stretched.
If a print job has already been received,the printer searches for the first punch
at reduced print speed. The label material is wound forward by the distance
between the punch sensor and the printhead (70 mm). This distance is used
by the rewinder’s control electronics to calculate the diameter of the backing
paper roll already wound up. To enable the control electronics to calculate di-
ameters even when using continuous material, printing is also suspended for
the first 70 mm. Processing of the print job then commences at the print speed
set on the printer or by the print job.
Should operational issues occur, the rewinder is switched off automatically.
When the maximum diameter of the backing paper roll is reached, a corre-
sponding message is displayed and the rewinder is switched off automatically.
Dispenser Modes The following modes of operation are available for the dispenser:
•Dispenser Mode with Dispensing Edge Sensor:
Material is fed right up to the dispensing edge, that is the label to be dis-
pensed sticks to the dispensing edge (set dispensing position). The printer
only feeds the next unprinted label backwards underneath the printhead
and begins printing, once the previous label has been taken off.
•Dispenser Mode with Foot Switch:
Depressing the foot switch triggers the printing and dispensing of one la-
bel. The next unprinted label is immediately positioned under the print-
head.
See Activate/Deactivate Dispenser on page 20.

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Arrangement of the Connections
For information about using the network connection, please read topic section
Advanced Applications .
[12] Back view of the AP5.4 with mounted I/O board (accessory).
AStart/stop signal input:
(Optional) Connection for a treadle switch (signal starts the printer) or a
stacker (signal stops the printer).
BSerial Interface:
RS232 or RS422/485, on the optional available I/O board.
CSignal interface:
4 inputs / 3 outputs, belongs to the optional available I/O board.
CAUTION! - Additional equipment of poor quality can damage the printer
«Connect only devices that fulfill SELV circuit requirements to EN60950.
«Connect only original accessories.
AB
C
D
E
F
G
H
I
J
KL

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DKeyboard connection:
In offline mode, the keyboard can be used for data input and print job
selection.
ECentronics connection:
For parallel transfer of print data.
FUSB connection:
For serial transfer of print data.
GCard insert:
For CompactFlash cards, which can be used to save fonts, logos or
graphics.
HRS232 interface:
For serial transfer of print data.
IStatus LED/Ethernet
JNetwork connection:
Connection for an “Ethernet 10/100 Base T” network.
KPower supply:
Connection to the power supply using the supply cable provided.
LPower switch:
Turns printer on/off.

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Warning Signs at the Printer
[13] Warning signs at the AP 4.4/5.4.
The warning sign pictured in [13] above warns of the risk of getting hands, fin-
gers, loose clothing, jewellery, etc. drawn in between rotating parts of the print-
er (part no. A5346).
The warning sign pictured in [13] below warns of the risk of getting hands or
fingers burned at hot surfaces close to the printhead (part no. A5640).
«Immediately replace missing or unreadable warning signs!
WARNING
!
Pinch point.
Keep hands clear
of rollers.
A5346

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Control Panel (Display)
[14] Control panel for the AP5.4.
ADisplay
With 32 digits and two lines, the display shows the operating conditions
(modi) for parameters, values, status and errors. You can select the lan-
guage you want to use for the display. The backlight ensures good legibil-
ity.
BButton Functions
General: The buttons offer a multitude of operating functions. A logical
menu structure is used for operation. The meaning of each button varies
according to the operating condition and the menu item. Additionally, spe-
cial functions have been programmed for certain button combinations.
Despite this diverse range, it is possible to identify the following main func-
tions:
COnline Button
– Switches between online and offline mode.
– Confirms inputs, menu items or displays.
– Selecting print jobs and inputting field values in standalone mode.
DCut Button
– Triggers a cut. Requirements:
– Cutter fitted and activated
– Printer offline
– Additionally, directs to deeper levels within the menu structure and se-
lects menu items
– Reduces values
EFeed Button
– Feeds material when the device is offline
– Starts the printing process, once feed has been stopped (in online
mode)
A
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– Additionally, directs to deeper levels within the menu structure and se-
lects menu items
– Enlarges values
FProg Button
– Calls up the parameters menu when offline
– Goes back one step in the parameters menu, and/or quits the parame-
ters menu.
For more detailed descriptions of the button functions, please see
•Sections Operation in Offline Mode on page 21 and Operation in Online
Mode on page 22.
•Section „Info-Printouts and Parameters”.
Operating State
Offline Mode
No jobs are waiting to be processed.
Printer settings can be made when the device is offline. The offline mode is
normallyactivewhentheprinterisswitchedon.Print jobs are received, but not
processed, via the selected interface.
¯To adjust the printer so that it goes online directly after you have switched
it on, set SYSTEM PARAMETER > Turn-on mode to Online:
Online Mode In the online mode, print jobs are received and processed immediately.
•No jobs are waiting to be processed.
•Current data transfer to the printer is shown on the display: This is indicat-
ed on the right, underneath the number of loaded jobs.
Another point on half line height above the first shows the interpreter sta-
tus:
–No point: No data to interpete.
–Solid point: The interpreter is busy (still data left in the spooler).
–Flashing point: The interpreter is waiting for data required to complete
a command (no data in the spooler).
•During printing, the display also shows the number of print jobs read (13)
and the remaining number of labels (25) to be printed in the current job.
•If a print job recognizes an infinite number of labels to be printed, then the
remaining number for this job is also shown as infinite.
OFFLINE 0 JOBS
ONLINE 0 JOBS
ONLINE 0: JOBS
ONLINE 13 JOBS
Restcount: 25
ONLINE 13 JOBS
Restcount: endless

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¯To stop printing, press the online button.
Message Mode The printer uses the message mode to signal an error or a particular operating
status. Message mode indicates that the printer is waiting to quit or for a fault
to be corrected. When exiting, the printer switches from message mode to of-
fline mode (depending on the error and the progress of the previous process).
Messages are made up of the status number and a brief descriptive text:
The messages 5001 (see above) e.g. occurs, if the printer is set for using la-
belling material with perforation, but continuous form material without perfora-
tion is inserted. In this example, the printer will continue to feed the material
for a few seconds before it finally sends an error message.
More information on message reports and a detailed list of all messages can
be found in topic section Status Messages .
Standalone Mode (For AP5.4 only)
In standalone mode, the print jobs are not transmitted via a data cable, but are
stored on a CF-Card. From there, they can be selected using the printer dis-
play or an keyboard connected to the printer.
For detailed information about using the standalone mode, refer to topic
section Advanced Applications .
Status 5001
No punch detected

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Basic Operating Procedures
Connecting the Printer
1. Ensure that the printer power switch is set to “0” (Off).
2. Connect the printer to the power supply using the cable provided.
3. Using the data cable supplied, connect the Centronics interface on the
printer to the host computer.
4. Turn on the printer using the power switch (switch to position “1”).
– The boot loader has started.
– Valid firmware program recognized, program will be started.
– Printer type (here: AP5.4)
Version number of the printer firmware.
– Internal RAM (here: 8 MB)
Optional RAM on the CompactFlash card (here: 32 MB) – only dis-
played when a CompactFlash card is in use.
– Offline mode
WARNING!
Printer is driven by mains voltage! Touching of live parts can cause life-
threatening body currents and burns!
«Make sure, that the machine is switched off, before connecting the po-
wer cable.
«Only connect the printer to a power socket that provides the correct
voltage, which can be found on the rating plate.
«Only connect the printer to a grounded power socket fitted to authori-
zed standards.
«When laying the power supply cable, ensure that:
a) no one can trip over it.
b) no one can step on it.
c) the power supply cable can be pulled out of the power outlet, if
necessary.
System start...
System start...
Start user prog
Avery AP5.4
V 1.02
Memory: 8MB
Flashcard: 32MB
OFFLINE 0 JOBS

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5. By pressing the online button you can switch to the online mode:
¯When the parameter SYSTEMPARAMETER >Turn-on mode is set to Online, the
printer switches directly to online mode when it is turned on!
Setting the Interface
According to the factory settings, the AP4.4/5.4 is set for data transfer via the
Centronics interface. Print data can also alternately be transferred via the
RS232, USB or Ethernet interface (AP5.4 only).
«Settings for the interfaces are made using the following parameter:
Set INTERF. PARAM. > EASYPLUGINTERPR to Interface
To find out how to set parameters, see topic section “Info-Printouts and
Parameters”.
For part numbers of of power or data cables refer to topic section
„Accessories“.
For detailed information about using the Ethernet interface, refer to topic
section Advanced Applications .
Activate/Deactivate Internal Rewinder
¯Only applies to the model AP5.4 with internal rewinder and deflector!
Deactivate «Set SYSTEM PARAMETER > Periph. Device to None
¯If you do not insert printing material before activating the rewind function,
an error message will be displayed.
For details on how to insert printing material, see topic Setup , section ”In-
serting Label Stock”.
Activate 1. Call SYSTEM PARAMETER > Periph. Device to Intern Rewinder
¯Not to be confused with Rewinder - this parameter activates the exter-
nal winder (optional extra)!
Upon activation, the rotational direction of the rewinder is set.
Facing outside is the default setting.
2. Press the Cut/Feed button to change the rotation direction.
3. Press Enter to confirm your setting.
The printer is restarted. The main menu now contains the additional menu
REWINDER PARA, which holds the parameter Rewind direction. This can be
used to change the rotational direction again.
During initialisation, the printer attempts to stretch the label material.
ONLINE 0 JOBS
Rewinder direct.
Facing outside

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Possible Errors Shortly after activating the internal rewinder, the following error message may
be displayed:
Possible causes:
•No printing material has been inserted, or the material’s end was not fixed
to the rewinder. Attach the end to the rewinder and press the Online button.
•The printing material is not stretched taut. Press the Online button.
The printer is now ready for the next print job. As soon as the print job is re-
ceived, the rewinder’s control electronics analyse the material width and print
speed as specified by the print job and calculate basic initialisation settingsfor
the rewinding process. These settings cover most areas of application.
In some challenging applications, a reduced impression accuracy may occur.
In cases like these, the basic initialisation settings can be changed. This may
be necessary in the case of:
•Very small labels
•Very rough backing paper
•Backing paper much heavier than label
•Labels stuck to backing paper
•Backing paper perforated along label contour
¯Basic initialisation settings may only be changed by a qualified authorised
service technician!
Activate/Deactivate Dispenser
¯Only applies to the model AP5.4 with internal rewinder and dispensing
edge!
Deactivate «Set SYSTEM PARAMETER > Periph. Device to None
Activate «Call SYSTEM PARAMETER > Periph. Device to Dispenser
The printer is restarted. The main menu now contains the additional menu
DISPENSER PARA , which holds the parameters required for dispenser opera-
tion:
For more details on the listed parameters, see topic Info- Printouts and Para-
meters , section ”Operating the Parameter Menu”.
Status 5004
Rewinder mat. tear
Parameter Possible Settings
Dispenser Mode Real 1:1 mode (default), batch mode, normal 1:1 mode
Dispensing Position Set in millimeters (default: 0.0mm)
Display Mode Job rest quant. (default), Dispense counter
Dispense counter Preset Amount (default: 0)
Application Mode Safe Mode (default), Immediate Mode
Start Mode Edge (default), Level low active
Start Source Foot switch (default), Light barrier
[Tab. 1] Parameters in the menu DISPENSER PARA.